Article of footwear with improved structure

ABSTRACT

An article of footwear including a first envelope, the first envelope extending lengthwise from a rear end to a front end, widthwise between a lateral side and a medial side, and heightwise from a bottom to a top end. The article of footwear further includes a functional component arranged opposite the first envelope, as well as a positioner to position the functional component with respect to the envelope.

BACKGROUND

1. Field of the Invention

The invention relates to an article of footwear, such as a shoe or anyequivalent, and to a method for manufacturing the article of footwear.The article of footwear can be used in fields such as walking, runningon flat or mountainous terrain, skateboarding, ball-playing sports,cross-country skiing, snowboarding, snowshoeing, and the like.

2. Description of the Background

An article of footwear must fulfill various and sometimes contradictoryfunctions, such as providing adequate support and/or tightening of thefoot while providing satisfactory comfort for the foot. The article offootwear must also have a certain flexibility, a property that involvesgood deformability to certain deformations of the foot. In other words,the article of footwear must adapt to the foot while allowing it to havethe freedom required for walking or practicing the sport involved.

To this end, it is a known and widely used practice to make articles offootwear, such as shoes, by combining an upper and a sole assembly. Theupper generally includes a number of components, such as a lateralquarter, a medial quarter, a vamp, a tongue, a heel, a rear counter, aprotective toe-cap, a tightening device including keepers and a lace, aninner lining, and may have other components. Moreover, some of thesecomponents may include a plurality of portions. The main problem with ashoe is in assembling and turning components that are cut and assembledflat into a three-dimensional shape. Conventionally, the upper isassociated with a lasting sole to demarcate a footwear element.According to a first method, the upper is glued to the lasting soleusing an adhesive layer. The lasting sole, also referred to as thelasting board, is relatively rigid to withstand the assembly process.The gluing operation is carried out by pulling the upper and pressing itflat onto the lasting board, with a last being inserted in the upper.This is known as the traditional shoe lasting assembly. This techniquemakes it possible to exert sufficient pressure when heating the adhesivein order to obtain the footwear element. A second method, also known,involves obtaining the footwear element by stitching the upper to thelasting board. This is referred to as the Strobel assembly. The lastingboard in this case is a flexible stitchable sole, referred to as theStrobel sole. For each of the first and second methods, the lastingboard is integral with the sole assembly. The sole assembly furthercomprises external components, such as one or more damping layers and awear layer adapted to contact the ground, which are generally attachedusing an adhesive to the lasted board and the lasted upper. The soleassembly further comprises one or more inner layers arranged in thefootwear element to fulfill protective functions in terms of hygiene,shock-absorption, arch of the foot support, or the like. Finally, theassociation of the footwear element with the other constituentcomponents of the sole assembly forms the shoe.

Irrespective of the method used for its manufacture, a prior art shoeproduced by the most widely used techniques has certain disadvantages.First, the shoe uses a large number of components, typically betweenforty and sixty components. Such a large number of shoe-formingcomponents increases the number of manufacturing operations and the timerequired to carry out such operations. It usually takes forty minutes toone hour and thirty minutes to make a shoe. It can be said that shoesmanufactured using conventional techniques are complicated, both by thenumber of their components and the number of manufacturing operations.

Another disadvantage results from the structure discontinuity of theshoe, in particular in the area of the upper. For example, a componentof reduced size superimposed on another, larger component, mayconsiderably modify the bendability of the upper in the location of thesmall component. This may hinder a user and also render the shaping,i.e., three-dimensional shaping, of the upper more difficult.

A further disadvantage is due to the presence of free spaces between thefoot and the shoe. This means that the foot is not in contact with theupper or the sole assembly in certain locations. This is especially truein the area of certain portions of the junction between the upper andthe lasting board. As a result, undesired displacements occur sometimesbetween the foot and the shoe, which can cause discomfort or injuries.Also, spaces sometimes appear between the foot, the ankle, or the lowerleg and the upper, in the area of the foot-insertion opening.Consequently, undesired foreign bodies may penetrate into the shoe.

Finally, it can be said that a shoe according to the prior art does notalways ensure adequate support and/or tightening of the foot, or doesnot always provide satisfactory comfort for the foot. Moreover, thisshoe does not systematically conform to all foot deformations.

In view of the foregoing, the Applicant has proposed an alternativeapproach to making an article of footwear.

For example, according to document FR 2 999 881, an article of footwearcomprises a first envelope, the first envelope extending lengthwise froma rear end to a front end, widthwise between a lateral side and a medialside, and heightwise from a bottom to a top end, the first envelopeincluding yarns linked to one another mechanically.

The first envelope is shaped into a three-dimensional volume upon beingpositioned on a last in order to have a geometry that is very similar tothat of a foot, and thereby closely conforms to the shape of the foot ina very uniform fashion. This means that the foot is in contact with, orat least very close to, the first envelope. This results in an evenlydistributed support of the foot, with very few or no undesireddisplacements between the foot and the first envelope. A resultingadvantage is increased comfort of the article of footwear, compared to ashoe according to the prior art.

From the arrangement according to the document FR 2 999 881, the firstenvelope has a structure continuity, in the sense that its inner surfaceand/or outer surface are at least substantially uniform, if notcompletely uniform. This advantageously results in less or no discomfortfor the user.

A synthesis of the foregoing shows that the first envelope supports thefoot and provides adequate comfort therefor. Furthermore, the firstenvelope is capable of conforming to the foot deformations. This enablesthe article of footwear according to the document FR 2 999 881 to fitcomfortably in any situation, be it a static or dynamic situation.

A further consequence of the arrangement according to the document FR 2999 881 is a reduced number of components for manufacturing the articleof footwear.

SUMMARY

To this end, the invention generally aims to improve an article offootwear. More specifically, the invention, for example, aims to improvethe transmission of steering forces, the restitution of reactions fromthe ground or an apparatus, or the perception of sensory information.The invention aims to optimize usage efficiency and to reduce userfatigue. The invention further aims to meet the specific needs of a userby preserving its basic qualities, such as comfort and foot support.This is a real challenge when support or transmission of intenseinformation is desired, for example during a sporting activity. Indeed,comfort and optimization in the transmission of forces are concepts thatare a priori contradictory.

In order to solve the aforementioned problem, the invention proposes anarticle of footwear comprising a first envelope, the first envelopeextending lengthwise from a rear end to a front end, widthwise between alateral side and a medial side, and heightwise from a bottom to a topend. For certain embodiments, as described below, the first envelopecomprises yarns that are linked to one another mechanically. The articleof footwear according to the invention comprises a functional componentarranged opposite the first envelope, as well as a means for positioningthe functional component with respect to the envelope.

This enables the envelope to have one or more specific properties at agiven location. For example, as explained in the following description,the functional component may be a tubular section located in ametatarsal zone. This section is intended to locally increase theresistance of the envelope to transverse deformation. In fact, this isto facilitate support in the area of the metatarsus. As a result, thearticle of footwear is adapted to a practice that requires transmissionof rather intense sensory information, steering forces, or groundreactions. This is the case when racing on rough terrain. But this isonly an example, and the invention, as explained below, provides otherpossible functions for an added component.

Among the resulting advantages of this arrangement are optimized usageefficiency and reduced user fatigue. The addition of the functionalcomponent preserves the basic qualities of the envelope, namely comfortand foot support. As a result, the invention is, for example, capable ofreconciling the two characteristics, including comfort and precision inthe transmissions, which are a priori contradictory.

It is further shown below that the invention also relates to a methodthat enables the article of footwear to be manufactured more easily.

Generally speaking, it can be said that the invention improves thestructure and method of manufacture of an article of footwear.

BRIEF DESCRIPTION OF THE DRAWINGS

Other characteristics and advantages of the invention will be betterunderstood from the description which follows, with reference to theannexed drawings illustrating, by way of non-limiting embodiments, howthe invention can be made, and in which:

FIG. 1 is a perspective front view of an article of footwear accordingto a first embodiment of the invention;

FIG. 2 is a cross section along the line II-II of FIG. 1;

FIG. 3 is a perspective schematic view of a preform and a functionalcomponent prior to assembly to one another, the preform being used tomanufacture a first envelope and a second envelope of the article offootwear according to FIG. 1;

FIG. 4 is similar to FIG. 3, in the case in which the preform and thefunctional component are assembled to one another;

FIG. 5 is a schematic view related to the construction of an envelope ofthe article of footwear according to FIG. 1;

FIG. 6 is another schematic view related to the construction of anenvelope of the article of footwear according to FIG. 1;

FIG. 7 is another schematic view related to the construction of anenvelope of the article of footwear according to FIG. 1;

FIG. 8 is a side view of a reinforcement configured to be integratedinto the article of footwear according to FIG. 1;

FIG. 9 is a perspective view related to the manufacture of the articleof footwear according to FIG. 1;

FIG. 10 is another perspective view related to the manufacture of thearticle of footwear according to FIG. 1;

FIG. 11 is a perspective schematic view of a preform used to manufacturea first envelope, according to a second embodiment of the invention;

FIG. 12 is a perspective front view of an article of footwear, top side,manufactured from the preform of FIG. 11;

FIG. 13 is a perspective schematic front view of a preform used tomanufacture a first envelope, the preform receiving functionalcomponents, according to a third embodiment of the invention; and

FIG. 14 is a view similar to FIG. 13, in the case in which thefunctional components are not yet associated with the preform.

DETAILED DESCRIPTION

The first embodiment described below relates, for example, to an articleof footwear for walking or running on flat or mountainous terrain.However, the first embodiment is applicable to other fields, such asthose mentioned above.

The first embodiment is described below with reference to FIGS. 1 to 10.

As shown in FIGS. 1 and 2, an article of footwear 1 is provided toreceive the foot of the user. For convenience, the article of footwear 1will be considered as a shoe in the following description although, aswill be shown in detail, its structure is completely unusual. Thus, theshoe 1 extends lengthwise along a longitudinal direction L, between arear end or heel 4 and a front end or tip 5, and widthwise along atransverse direction W, between a lateral side 6 and a medial side 7.

As shown, the upper of the shoe 1 comprises a lower portion 10, providedto surround the foot, and has no upper portion. Alternatively, however,an upper of a shoe of the invention encompasses one having both a lowerportion and an upper portion, the latter being provided to surround theankle and possibly the lower leg.

According to the first embodiment described, the shoe 1 extendsheightwise from a bottom 12 to a top end 13, that is to say, up to thefree end of the lower portion 10 or of the shoe 1. The bottom is asubdivision of the shoe, on which the foot takes support.

The shoe 1 is structured to allow good foot rolling movement duringwalking, transmission of sensory information and forces when takingsupport or jump landing. Therefore, the shoe 1, or article of footwear,is relatively flexible.

As described in detail below, the shoe 1 comprises a first envelope 21extending lengthwise along the longitudinal direction L, from a rear end24 to a front end 25, widthwise along the transverse direction W,between a lateral side 26 and a medial side 27, and heightwise from abottom 28 to a top end 29. This enables the first envelope to surroundand support the foot of the user. For its construction, the firstenvelope includes yarns linked to one another mechanically, as explainedbelow. Also, at least a portion of the yarns of the first envelopecomprises at least one hot-melt filament, as also explained below.

According to the first embodiment, and in a non-limiting manner, theyarns of the first envelope, comprising at least one hot-melt filament,are distributed over the entire first envelope 21, and the melting ofthe yarns during manufacture contributes, to a greater or lesser extent,depending on their quantity and concentration, to the strength and/orthe adhesion and/or the abrasion resistance of the first envelope. Infact, the melting of the yarns enables the first envelope 21 to retainits shape by itself. This means that it does not collapse if no externalforce is applied thereto, even if it is not associated with othercomponents. It can be said that the first envelope 21 is a unitarycomponent, on the one hand, and that it can form a self-supportingcomponent, on the other hand, giving shape to the shoe, to a greater orlesser extent, as a function of the quantity/concentration of the yarns.Accordingly, the first envelope 21 provides shape to the shoe 1. Inother words, the rear end 24, the front end 25, the lateral side 26 anda medial side 27, the bottom 28 and the top end 29 of the first envelopedemarcate the rear end 4, the front end 5, the lateral side 6, themedial side 7, the bottom 12 and the top end 13, respectively, of thearticle of footwear or shoe 1. The minimalist structure used for theenvelope 21 ensures simplicity, lightness, and many other advantages, asexplained below.

Without limitation, and still according to the first embodiment of theinvention, the shoe 1 also includes a second envelope 31 extendinglengthwise along the longitudinal direction L, from a rear end 34 to afront end 35, widthwise along the transverse direction W, between alateral side 36 and a medial side 37, and heightwise from a bottom 38 toa top end 39. The second envelope 31 also covers the foot, in the samefashion as the first envelope 21. The second envelope 31 is arrangedoutside of the first envelope 21 and, thereby, indirectly covers thefoot. The final shape of the shoe 1 is provided by both the firstenvelope 21 and the second envelope 31. The advantage of using twoenvelopes will be more apparent below.

Still in the context of the invention, the second envelope 31 comprisesyarns linked to one another mechanically, at least a portion of theyarns comprising at least one hot-melt filament, the yarns comprising atleast one hot-melt filament being distributed over the entire secondenvelope 31, and the shape of the second envelope being solidifiedthrough melting of the yarns comprising at least one hot-melt filament.Here again, the melting enables the second envelope 31 to maintain itsshape by itself. This means that it does not collapse if no externalforce is applied thereto, even if it is not associated with othercomponents. It can be said that the second envelope 31 is a unitarycomponent, on the one hand, and that it can form a self-supportingcomponent, on the other hand, giving shape to the shoe, to a greater orlesser extent, as a function of the quantity/concentration of the yarns.Consequently, the second envelope 31 also provides shape of the shoe 1.In other words, the rear end 34, the front end 35, the lateral side 36,the medial side 37, the bottom 38, and the top end 39 of the secondenvelope 31 also demarcate the rear end 4, the front end 5, the lateralside 6, the medial side 7, the bottom 12, and the top end 13,respectively, of the article of footwear or shoe 1. The minimaliststructure used for the envelope 31 ensures simplicity, lightness, andmany other advantages, as explained below.

To better highlight the specificities of the invention, it is useful todescribe how the envelopes 21, 31 are manufactured. This is done belowwith reference to FIGS. 3 to 7 in particular.

As initially shown schematically in FIGS. 3 and 4, each envelope 21, 31is obtained by manufacturing a sleeve 41, that is to say, a flexibletube made of yarns linked to one another mechanically. Alternatively, itcan be said that an envelope 21, 31 is a sock, as explained below withregard to all the drawing figures. The sleeve 41 is a preform for makingthe article of footwear 1. Without limitation, and in connection withthe first embodiment, the sleeve 41 makes it possible to obtain both thefirst envelope 21 and the second envelope 31. The sleeve 41 extendslengthwise from a first end 42 to a second end 43. The first end 42 isclosed using any technique known to one with ordinary skill in the art,such as stitching after folding, adding an end piece made of yarnslinked to one another mechanically, or any equivalent. The second end 43is merely an opening.

The sleeve 41 makes it possible to manufacture the envelopes 21, 31 inone piece. Here, the first envelope 21 and second envelope 31 arecoextensive. This simplifies the manufacture by reducing the number ofcomponents and the time required for implementation.

The association of the yarns used to make the sleeve 41, and thereforethe envelopes 21, 31, is presented with reference to FIGS. 5 and 6.Generally speaking, the yarns are provided to be associated with oneanother using any suitable textile technique, such as knitting, weaving,braiding, or the like. In the case of knitting, it is possible to use asingle- or double-knit circular knitting machine, a cylinder knittingmachine, or a flat knitting machine. Two knitting zones may be joined toone another using the intarsia knitting technique or embroidery. Variousdecorative patterns can be obtained directly when knitting with theIntarsia method, embroidery, the Jacquard knitting technique, or thelike. FIG. 5 shows a conventional weaving with first yarns 44 orientedalong a first direction, second yarns 45 oriented along a seconddirection, the first 44 and second 45 yarns intersecting to form aflexible mesh. FIG. 6 shows knitting with three yarns 45, 47, 48arranged in interpenetrating loops. However, a number of otherarrangements are possible.

The sleeve 41 is manufactured, for example, with a flat knittingmachine, which makes it possible to vary the cross section, that is tosay, the diameter of the sleeve, to make shape variations for the heel,to create openings for passage of the laces, to vary the thickness ofthe wall of the sleeve, or in particular to vary the tightening of theloops. In fact, the flat knitting machine provides a wide range ofadjustment possibilities, and it is adapted to make sleeves of allsizes, whether in diameter or in length. As such, the flat knitting ismore practical than the circular knitting machine. Indeed, the circularknitting machine works on a reduced range in the area of the sleevediameter. It is therefore necessary to use a plurality of differentcircular knitting machines to make a complete line of sleeves 41, thatis to say, a complete line of shoes encompassing all shoe sizes, where asingle flat knitting machine would be sufficient. In the end, a flatknitting machine makes it possible to make one or more three-dimensionalenvelopes, with all desired features, and to the desired shoe size.

A yarn within the context of the invention will next be defined.

First, the yarn may be a monofilament obtained, for example, byextruding a hot-melt synthetic material, such as polyamide,polyurethane, polyethylene, or any equivalent or similar material. Theproduction of a filament is continuous, in a way comparable to silkfilament produced by a spider. The filament may be mono-component ormono-material, in the sense that its transverse cross section isuniform. But the filament may also be multi-component, e.g.,bi-component. In this latter case, a transverse cross section of afilament shows a core comprised of a first material, and a peripheralenvelope surrounding the core, such envelope being comprised of a secondmaterial. Each material may be hot-melt, or only one material may behot-melt. If both materials are hot-melt, their melting temperatures aredifferent.

Next, the yarn may be multi-filament. In this case, it is obtained byassociating a plurality of filaments. Such an association isschematically shown in FIG. 7. Here, all of the filaments 49 are of thesame type, in the sense that each has the same melting point. Butcombinations of filaments of different types can be provided, some ofwhich may be meltable and others may not, or may have different meltingpoints. The filaments are associated with one another by any knowntechnique.

Furthermore, the yarn can be obtained in the form of a fiber mesh. Here,a fiber is a filament of limited length. The fibers are associated intight contact to form the mesh, by any known technique, and especiallyby twisting. Fibers, especially natural fibers such as cotton, aretraditionally kept together by friction. However, for the invention, thefibers are kept together either by friction or a combination of frictionand melt-adhesion, or yet entirely by adhesion, because the inventionuses hot-melt materials.

Having generally presented the structure of the sleeve 41, its use forthe manufacture of the shoe 1 can now be explained. However, to remainin the context of the first embodiment, it is useful to first explainthat the article of footwear 1, or shoe, includes a reinforcement 51. Itis shown more clearly below that this reinforcement is associated withthe envelopes 21, 31 by nesting at the time of manufacture of the shoe1, in order to provide the latter with specific capabilities.

As shown in FIG. 8, the reinforcement 51 is a component extendinglengthwise from a rear end 54 to a front end 55, widthwise between alateral side 56 and a medial side 57, and heightwise from a bottom 58 toa top end 59. The reinforcement 51 has a length and a width similar tothe lengths and widths of the envelopes 21, 31. More specifically, thereinforcement 51 extends lengthwise, in relation to the first envelope21, from the rear end 24 to the front end 25, widthwise between thelateral side 26 and the medial side 27, and heightwise from the bottom28 to the top end 29. By definition, this makes it possible to reinforcethe first envelope 21, and therefore the article of footwear 1, inparticular in the area of the bottom 12 and at the periphery of thebottom.

In a non-limiting fashion, the reinforcement 51 carries a tighteningdevice 61. The tightening device, for example, includes keepers 62located in the area of the top end 59, as well as a lace 63 and ablocking device 64, known to one with ordinary skill in the art. It istherefore possible to tighten or loosen the reinforcement 51 and,thereby, to tighten or loosen the shoe 1, as will be more apparentbelow. Other tightening means may be provided.

According to the invention, as is generally understood with reference toFIGS. 1 to 10, the article of footwear 1 comprises a functionalcomponent 71 arranged opposite the first envelope 21, as well as apositioner for positioning the functional component 71 with respect tothe envelope. It will be shown below that, according to the firstembodiment, the functional component 71 provides the article of footwear1 with specific localized mechanical properties. The positioner, whichis described below, enables the functional component 71 to be positionedprecisely on the first envelope 21 and, therefore, ultimately on thearticle of footwear 1. Given that the article of footwear 1 is athree-dimensional object, the invention enables positioning of thefunctional component on a volume. In fact, the functional component 71has a three-dimensional structure. This structure has a shape identicalor similar to the surface to which it must conform. This facilitates itspositioning and enables it to be positioned at the desired location.

Given that the article of footwear 1 has concave portions and/or convexportions, the functional component 71, in most cases, also has concaveportions and/or convex portions due to its conformability properties,conferred by the deformation of its mechanical structure (meshes) and/orthe use of elastane filaments and/or elastic filaments.

In the specific case of the first embodiment of the invention, thefunctional component 71 is made from a tubular section, that is to say,a sleeve portion or sock portion. This makes it possible to arrange itat the desired location opposite the envelopes 21, 31 by slipping itonto one of the two, or on both at the same time. The sock may be devoidof a heel, or may comprise one or more heels, and the sock may be closedat one or both ends. When the functional component is in the form of asock or an ankle sock, it makes it possible to further obtain a veryprecise longitudinal positioning on the envelope 21, 31, due to thestops formed by the heel and front end of the ankle sock.

For example, in a non-limiting manner, the functional component 71 isarranged on the first envelope 21. In order to understand its role, itshould be noted that the article 1 has four successive zones, from therear end 4 to the front end 5. These zones include a heel zone 72, anarch of the foot zone 73, a metatarsal zone 74, and a front zone forreceiving the toes. For the first embodiment of the invention, thefunctional component is located in the metatarsal zone. In fact, thefunctional component completely bypasses the metatarsal zone, by beingoriented in a transverse plane of the article of footwear 1. Thisprovides the latter with greater resistance to transverse deformations.A resulting advantage is better support on the ground in the area of themetatarsus, with greater transverse stability.

Still in a non-limiting fashion, as will be more apparent below, thefunctional component 71 is housed between the first envelope 21 and thesecond envelope 31. This facilitates its integration into the article 1.

As is the case for the envelopes 21, 31, the functional component 71comprises yarns 44 to 48 linked to one another mechanically, at least aportion of the yarns comprising at least one hot-melt filament 49. Thismakes it possible to provide at least one subdivision of the functionalcomponent 71, with a stable self-supporting structure once melting hasbeen carried out.

Here, the yarns comprising at least one hot-melt filament aredistributed over the entire functional component 71, and the shape ofthe functional component 71 may or may not be solidified by the meltingof the yarns comprising at least one hot-melt filament.

In a non-limiting fashion, and still according to the first embodimentof the invention, the positioner for positioning the functionalcomponent 71 in relation to the first envelope 21 comprises reversiblyextensible yarns, in addition to the tubular shape of the sleeveportion, the yarns being associated with the structure of the functionalcomponent. This means that a portion of the yarns forming the functionalcomponent are elastic. These yarns are made of elastane, for example. Inpractice, the functional component 71, that is to say, the sleeveportion, due to its tubular shape and the presence of extensible yarns,is slipped onto and positioned at the desired location around the firstenvelope 21, as will be understood below.

Next explained is the use of the sleeve 41 for the manufacture of theshoe 1, according to FIGS. 9 and 10. In fact, the components of the shoe1 are assembled by hand, without a complex and expensive machine, as wasthe case for the prior art.

It can be understood from FIGS. 9 and 10 that the sleeve 41 is fittedonto a component 76 referred to as a last, shaped to emulate the foot ofa user. The sleeve is applied to the last 76 in the manner of a sock ona foot. The sleeve 41 conforms to the shape of the last 76 due to itselasticity, which is inherent in its textile structure. The elasticitythat enables shaping of the sleeve 41 is due to a reversible elasticdeformation of the constituent meshes of the sleeve. Then, thefunctional component 71, in this case the sleeve portion, is slippedonto the last 76 around the first envelope 21 at the desired location,in this case in the metatarsal zone 74. The elasticity holds it in thedesired position, because it exerts restraint on the last and on thefirst envelope. Then, the reinforcement 51 is nested on the subdivisionof the sleeve 41 which becomes the first envelope 21. Then, thesubdivision of the sleeve 41 that becomes the second envelope 31 isfolded over the reinforcement 51, thereby covering the latter and thesubdivision assigned to the first envelope and the functional component71. This is sufficient to form the subassembly of the shoe 1 thatenvelopes the foot, a subassembly that ultimately includes the firstenvelope 21, the functional component 71, the reinforcement 51, and thesecond envelope 31. The second envelope 31 has an opening 77 for passageof the lace 63. It then suffices to subject the subassembly to a highertemperature, using any suitable technique, to melt the hot-meltfilaments of the envelopes and of the functional component 71 only asappropriate, and thus provide the shoe 1 with its geometry, among otherthings. In the present case, the functional component 71 improves theassembly resistance to deformation, in the manner of a torsion box,which is particularly important in the metatarsal zone to give morestability to the assembly. After heating, the last 76 may be removedfrom the subassembly. The shoe 1 is then almost finished. It suffices,according to the first embodiment, to add an outer sole assembly 78thereto. As shown in FIGS. 1 and 2, the article of footwear 1, or shoe,comprises an outer sole assembly 78. This outer sole assembly is adaptedto take support on the ground and, therefore, is structured to resistwear by friction and also to dampen impacts. It thus includes a wearlayer 79 and a damping layer 80, for example. FIG. 2, which is atransverse cross section in the region of the shoe configured to receivethe arch of the foot, shows that the bottom 12 has a non-planargeometry, substantially identical to that of the aforementioned arch.The shoe 1 according to the invention is indeed capable, as has beenmentioned, of conforming to the shape of the foot. It is thus notnecessary to add an inner sole to the shoe 1 to reproduce the arch ofthe foot, or the other aspects of the bottom of the foot. This thussimplifies the shoe 1 according to the invention, compared to a priorart shoe. This also lightens the shoe 1 and thereby reduces themechanical inertias. A resulting advantage is improved athleticperformance. The shoe according to the invention is well suited, forexample, to a long-distance runner.

FIG. 2 also shows that the reinforcement 51 is located between the firstenvelope 21 and the second envelope 31. As a corollary, the tighteningdevice 61 is also mainly located between the first envelope 21 and thesecond envelope 31. This preserves the tightening device, for example bypreventing the lace 63 from catching branches during a race in theforest.

Still with reference to FIG. 2, but also to FIG. 1, the first envelope21 and second envelope 31 are shown to be continuous along a transversecross section. These envelopes therefore extend continuously in the areaof their respective upper ends 29, 39, and thus in the area of the topend 13 of the shoe.

As understood from FIG. 1, but also from FIG. 3 or 4, the boundarybetween the first envelope 21 and the second envelope 31 is a fold 83demarcating a foot insertion opening 84. The periphery the footinsertion opening 84 is therefore demarcated simply by folding the twoenvelopes 21, 31 on one another. This means that this periphery does nothave a stitch or an attached element, as in the prior art and,therefore, that the shoe 1 does not cause discomfort to the user,including in the area of the opening 84.

By way of example, as seen in FIG. 3, or in FIG. 4, the first envelope21 has three zones 91, 92, 93 having different mechanical properties.These properties are dependent upon the percentage of hot-melt filamentscontained in the yarns. Without limitation, a first zone 91 with a highconcentration of hot-melt filaments, for example between 60 and 100%, isprovided here. The first zone 91 demarcates the bottom 28 and theperiphery of the bottom. A second or intermediate zone 92 with anaverage concentration of hot-melt filaments, for example between 30 and70%, is then provided. The second zone extends mainly in the area of thelateral 26 and medial 27 sides. A third zone 93 with a low concentrationof hot-melt filaments, for example between 5 and 40%, is finallyprovided. The third zone extends mainly in the area of the top end 29.This arrangement renders the first envelope 21 relatively inflexibletowards the bottom 28, but progressively flexible towards the top end29. The flexibility, or elasticity, is conditioned by the type ofknitting stitch loops and/or by the elasticity of the constituentmaterial of the stitch loops. This elasticity enables the first envelope21 to remain in contact with the foot, the ankle or the lower leg, andthereby prevents the intrusion of foreign bodies. An elastic yarn kepttensioned provides good foot support.

Similarly, the second envelope 31 has three zones 101, 102, 103 havingdifferent mechanical properties. These properties again are dependentupon the percentage of hot-melt filaments contained in the yarns.Without limitation, a first zone 101 with a high concentration ofhot-melt filaments, for example between 60 and 100%, is provided here.The first zone 101 demarcates the bottom 38 and the periphery of thebottom. An intermediate or second zone 102 with an average concentrationof hot-melt filaments, for example between 30 and 70%, is then provided.The second zone extends mainly in the area of the lateral 36 and medial37 sides. A third zone 103 with a low concentration of hot-meltfilaments, for example between 5 and 40%, is finally provided. The thirdzone extends mainly in the area of the top end 39. This arrangementrenders the second envelope 31 relatively inflexible towards the bottom38, but progressively flexible towards the top end 39. Here again, theflexibility towards the top end enables the second envelope 31 to remainpressed onto the foot, the ankle or the lower leg, and thereby preventsthe intrusion of foreign bodies. Again, an envelope comprising anelastic yarn kept tensioned provides good foot support.

For each envelope 21, 31, the melting of filaments determines thephysical or mechanical properties in proportion to the hot-meltfilaments. For example, the greater their number is, in percentage, thehigher the resistance to abrasion. Conversely, if the percentage ofhot-melt filaments is reduced, the elasticity is maintained. In otherwords, the higher the percentage of hot-melt filaments, the higher theresistance to abrasion and, by corollary, the elasticity is reduced.Conversely, if the percentage of hot-melt filaments is low, then theresistance to abrasion is low and, by corollary, the elasticity issignificant.

Ultimately, when the envelopes 21, 31 and the functional component 71are assembled, the flexibility of the shoe 1 increases vertically fromthe bottom 12 to the top end 13. This enables the shoe to support thefoot, on the one hand, and to reversibly widen in the area of the topend 13 in order to make it easier to put on or remove the shoe, on theother hand.

However, the aforementioned arrangements of the envelopes are notlimiting. In particular, each envelope and the functional component 71can be provided with the desired properties, such as elasticity,waterproofness, wear resistance, fungicidal properties, the desiredaesthetic appearance, or the like.

Still according to the first embodiment, the thickness of the firstenvelope 21 is less than or equal to 5.0 mm, considering that values ofless than or equal to 3.0 mm have yielded good results. This lightensthe first envelope 21.

Similarly, the thickness of the second envelope 31 is less than or equalto 5.0 mm, considering that values of less than or equal to 3.0 mm haveyielded good results. This lightens the second envelope 31.

The thickness of the functional component 71 is less than or equal to3.0 mm. This makes it lighter.

For each component 21, 31, 71, thickness is measured after melting ofthe yarns comprising at least one hot-melt filament.

Ultimately, the shoe 1 according to the invention is lighter than a shoeaccording to the prior art, with comparable technical specifications.

The other embodiments of the invention are briefly described below withreference to FIGS. 11 to 14. For reasons of convenience, mainly thedifferences from the first embodiment are identified. In addition, thesame reference numerals are used for identical or similar elements seenin the first embodiments.

Thus, the second embodiment, according to FIGS. 11 and 12, features anarticle of footwear or shoe 1 with a rear end 4 and a front end 5, alateral side 6 and a medial side 7, or a bottom 12 and a top end 13.

What is specific to the second embodiment is the structure of thepreform or sleeve 41. The sleeve extends well between a first end 42,which is for example closed, and a second open end 43. However, thesleeve 41 is sized to obtain the first envelope 21 only, to theexclusion of any other envelope or envelope subdivision. Accordingly, itis the open end 43 of the first envelope 21 which alone demarcates thefoot insertion opening 84. The shoe 1 according to the second embodimenttherefore comprises the first envelope 21, the functional component 71,and the reinforcement 51, with its tightening device 61, to theexclusion of any additional envelope. It can also be said that thereinforcement 51 covers the first envelope 21. This means that the shoe1 is further lighter than the shoe according to the first embodiment.Also provided is an outer sole assembly 78 for the shoe according to thesecond embodiment, although this is not essential.

For the third embodiment, according to FIGS. 13 and 14, there is asleeve 41 sized to obtain the first envelope 21 only.

What is specific to the second embodiment is that it comprises aplurality of functional components. In this case, the functionalcomponent 111, towards the rear 24, is a rear stiffener. It is also athree-dimensional element. Towards the front, the functional component121 is a front end piece. It is also a three-dimensional element. Theseelements 111, 121, for example, improve the resistance to abrasion, orprovide greater rigidity. The three-dimensional shape facilitatesplacement and positioning.

The invention is not limited to the embodiments described above, andincludes all technical equivalents that fall within the scope of theclaims that follow.

In particular, one or more functional components 71, 111, 121 may beprovided.

Each functional component is arranged either inside an envelope oroutside of an envelope, or between two envelopes, depending upon thedesired technical effects.

In certain cases, the positioner to position the functional component71, 111, 121 with respect to the envelope 21, 31 comprises an adhesiveproduct.

In other cases, the positioner to position the functional component withrespect to the envelope comprises fastening elements.

The invention is applicable to any type of shoe having an upper made ofa compatible material. In this case, the upper is mounted on a last, andthen the functional component having predetermined characteristics ispositioned on the upper and glued, before the outer sole assembly isfinally added.

The invention relates to a method for manufacturing an article offootwear comprising a first envelope, the first envelope extendinglengthwise from a rear end to a front end, widthwise between a lateralside and a medial side, and heightwise from a bottom to a top end, themethod comprising a step of adding a functional component to the lastedenvelope before assembly with an outer sole assembly.

In this manufacturing method according to the invention, the functionalcomponent is provided with a positioner, for example by using a tubularsection/sock portion or other three-dimensional shape enabling easypositioning, and also by using extensible material, for example for thetubular section/sock portion.

1-21. (canceled)
 22. Article of footwear comprising: a first envelopeextending lengthwise from a rear end to a front end, widthwise between alateral side and a medial side, and height-wise from a bottom to a topend; a functional component arranged opposite the first envelope; and afunctional component positioner configured to position the functionalcomponent in relation to the envelope.
 23. Article of footwear accordingto claim 22, wherein: the first envelope comprises yarns mechanicallylinked to one another.
 24. Article of footwear according to claim 22,wherein: the functional component has a three-dimensional structure. 25.Article of footwear according to claim 22, wherein: the functionalcomponent comprises yarns mechanically linked to one another; and atleast a portion of the yarns comprise at least one hot-melt filament.26. Article of footwear according to claim 25, wherein: the portion ofthe yarns that comprise at least one hot-melt filament are distributedover an entirety functional component.
 27. Article of footwear accordingto claim 22, wherein: the functional component is made from a tubularsection.
 28. Article of footwear according to claim 22, wherein: thefunctional component is located in a metatarsal zone.
 29. Article offootwear according to claim 22, wherein: the functional component is arear stiffener of the article of footwear.
 30. Article of footwearaccording to claim 22, wherein: the functional component is a frontend-piece.
 31. Article of footwear according to claim 22, wherein: thefunctional component positioner comprises reversibly extensible yarns,the yarns being associated with a structure of the functional component.32. Article of footwear according to claim 22, wherein: the functionalcomponent positioner comprises an adhesive product.
 33. Article offootwear according to claim 22, wherein: the functional componentpositioner comprises fastening elements.
 34. Article of footwearaccording to claim 22, wherein: at least a portion of the yarns of thefirst envelope comprises at least one hot-melt filament.
 35. Article offootwear according to claim 34, wherein: the yarns of the first envelopethat comprise at least one hot-melt filament are distributed over anentirety of the first envelope; and the melting of the yarns contributesto the strength and/or gluing and/or abrasion resistance of the firstenvelope.
 36. Article of footwear according to claim 22, furthercomprising: a second envelope extending lengthwise from a rear to afront end, widthwise between a lateral side to a medial side, andheightwise from a bottom to a top end.
 37. Article of footwear accordingto claim 36, wherein: the second envelope comprises yarns mechanicallylinked to one another mechanically; at least a portion of the yarnscomprising at least one hot-melt filament; the yarns comprising at leastone hot-melt filament being distributed over an entirety of the secondenvelope; and a shape of the second envelope being solidified by meltingthe yarns comprising at least one hot-melt filament.
 38. Article offootwear according to claim 36, wherein: the first envelope and secondenvelope are co-extensive.
 39. Article of footwear according to claim22, further comprising: a reinforcement carrying a tightening device.40. Article of footwear according to claim 22, further comprising: outersole assembly.
 41. Method of manufacture of an article of footwear thatincludes at least a first envelope extending lengthwise from a rear endto a front end, widthwise between a lateral side and a medial side, andheightwise from a bottom to a top end, said method comprising: fittingthe first envelope onto a last, thereby creating a lasted envelope;adding a functional component onto the lasted envelope; and assemblingan outer sole to the article of footwear, whereby the outer sole isassembled prior to the adding of the functional component.
 42. Method ofmanufacture according to claim 41, further comprising: providing thefunctional component with a functional component positioner configuredto position the functional component in relation to the envelope.